Tomberlin Emerge 500LE - Motor Problems,

Role

This cart has been a huge P in the A to say the least.

The motor stopped working. Took the motor off, took the motor to a local and well known repair shop. They put new brushes, cleaned the commutator.

Got home with it, put it on, it will do 1mph in forward and jerk and stop and do the same in reverse. Once you let off the accelerator and start over, it starts to move again before it jerks and does nothing again.

During all of this ^^^ 1mph, I walk around to the back and smell some burning. I start to feel the wires to the motor and they are pretty warm and these thicker gauge wires it takes a lot of resistance to cause them to get warm.

I pull the motor back off, spins freely, look to make sure the brushes aren't out of the holders, and i can't seem to find anything wrong with it.

I take it back to the guys that put the brushes in it, they inspect the brushes and commutator and were kind of scratching their head. So they pull the commutator and look to see if they see anything. They apparently thought it might be the commutator needing to be undercut to ensure it wasn't shorting it.

So I literally watched as they undercut it perfectly and made sure no contacts were touching. They put it all back together and sent me on my way.

Just put the motor back on an hour ago to find that I am right back where I started. Pretty aggravated at this point.

The only thing that I can be certain of the speed is not great enough to be "lymph" mode. My OEM level programmer sees no current faults. I cleared them all.

But what I do know for certain is that something is causing "some resistance" for the brush side of the motor to get so hot and the cables.

Scratching my head on this one. Motor has to be fine. Batteries are 50-51 volts at resting state, even under load, they are fine.

SO WHERE IS THE PROBLEM?!? ANY IDEAS?

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

Role

I'm getting somewhere but still have not figured it out. As I mentioned previously there were no current faults via my oem level programmer and I had already cleared history of faults.

The controller was not blinking any type of code, so I didn't really have anything to go by.

I removed main - neg and main + for 10-15 mins and drained the entire circuit, reconnected cables, turned key on, and noticed an error code was finally being given.

Flipped to tow, waited about 45 seconds, flipped back to run, turned key on selected Forward and pressed pedal
I repeated this twice ^ got two different error codes

1 flash, 5 flash
1 flash, 4 flash

According to Curtis 1268 controller information - that's HPD and Motor stall

The speed sensor is fine, and I know this because it came off of a cart that was working 5 mins prior to putting it on this motor.
I know the brushes have not really seated themself into a groove on the motors armature yet because the brushes are brand new. This might also be causing the cables to get pretty warm because it hasn't rounded the ends of the brushes yet against the commutator?

Motor Stall (1,5)
So I'm going to eliminate all of the following from the list of these two fault codes:
- too steep for vehicle weight (it's not even on a hill)
- mechanically locked motor (motor was just rebuilt and undercut - spins freely like butter and is as good as new)
- EM brake failure (because the E-brake switch opens, closes, and illuminates on the dash as it should)


-speed sensor defective (although the speed sensor itself is good, maybe the magnet? (By default the controller is set to 8 pole, but I notice the number of markings on this magnet are 4 poles - could that be a cause?

Moving to the other error code..
HPD (1,4)
High pedal disable fault - Improper sequence of direction and
throttle inputs - the micro switch in the floor is fine. Hall / ITS sensor is sending a signal because the rear wheels move, and on my programmer, the readings are spot on.. slowly shows 0, 15, 34,.. all the way to 100, and does the reverse going down, not jumping around.

So wondering, could a faulty solenoid be causing it?
Is there a way to "BY-PASS or Turn OFF HPD" to see if that fixes the issue?

Any ideas?

Golf cart guy

Got to this late, but it still sounds like motor. Ive seen too many times the guys that "know motors" get it wrong. If you had to take it back for they to checke the commutator, then they don't know motors or don't know golf cart motors.
With no fault codes coming it, its something the system doesn't recongnize.
Granted now you have HPD, and that will point to the Hall effect sensor. If the cart has been sitting for awhile, they tend to go bad siting.

Rooster59

Maybe you need to start your own thread in the proper category. This is about a Tomberlin cart. They are only electric. No rods or cylinders in an electric motor.